Best Practice Guide - Forklift Training Centre

1 2016 FTC South NZ Ltd Forklift SAFETY Page 1 Forklift Operator best Practice Guide Forklift Training Centre Lifting the Standards 2016 FTC South NZ Ltd Forklift SAFETY Page 2 FORWARD >>>>>>>>>> This booklet is not a prime reference for Forklift Training but rather a document that provides employers, business owners, Forklift operators and industry trainers with basic information about common dangers associated with Forklift operations, and ways to make workplaces safer. Whilst every effort has been made to ensure its accuracy, the contents of this booklet do not constitute legal advice and should not be relied on as such. This booklet does not over-ride legislation governing the operation of forklifts.

2 No liability is assumed by FTC South (NZ) Ltd for any losses by any person relying directly or indirectly on the contents of this booklet. If the user of this booklet is unsure whether the material is correct, they should refer to the relevant legislation or the manufactures operating manual. A Forklift operator course conducted by FTC South (NZ) Ltd satisfies the requirements of the Approved Code of Practice for Training Operators and Instructors of Powered Industrial Lift Trucks (Forklifts) . The main aim of the Forklift operator s course is to improve and develop operators operating techniques and to make them more aware of the safety and mechanical implications of their operating methods. FTC South (NZ) Ltd acknowledges the assistance of the Ministry of Business, Innovation and Employment (MBIE) and the New Zealand Transport Agency (NZTA) in the preparation of this handbook. Please note It is required that Forklift operator retraining is to be undertaken every three years.

3 Maurice Ridler Diploma Adult Education Director FTC South NZ Ltd 2016 FTC South NZ Ltd Forklift SAFETY Page 3 CONTENTS Legislation and Codes 4 NZ Transport Agency 4 Driver licence requirements 4 Road defined 4 Loading vehicles 5 Parking on a road 5 Forklift documentation 5 Dimensions and weights 5 Reduce the risk 5 Forklift Stability 5 Stability zone 6 Centre of gravity 6 Load Centre 7 Load capacity plate 7 Weight ratios 8 Weight terminology 9 De-rating 9 Attachments 9 Mast 9 Fork arm attachments 9 Forks 10 Raising people 10 Work platforms 10 Gas cylinder 10 Forklift safety 11 Forklift defined 11 Causes of Forklift accidents 11 Basic operator rules 11 Tip over 11 Safety rules general 12 Ramps and loading docks 12 Reach trucks 13 Pedestrian operated vehicles 13 Turning points 13 Stacking and De-Stacking 13 Basic stacking procedure 13 Basic de-stacking procedure 13 Speed 13 Braking distance 14 Maintenance 14 Common faults 14 Pre-operational checks 14 Daily check list 14 Design criteria 15 Components 15 Weights 16 2016 FTC South NZ Ltd Forklift SAFETY Page 4 LEGISLATION and CODES The Health and Safety at Work Act 2015 (HSWA)

4 Contains the New Zealand's workplace health and safety law. HSWA sets out the principles, duties and rights in relation to workplace health and safety. The Forklift Safety Standard (NZS/ANSI/ITSDF ) contains the safety standards for low and high lift trucks. The Powered Industrial Trucks General Requirements ( ) contains the requirement for the design, manufacturing, marking and testing of powered industrial lift trucks and their attachments. The Land Transport (Road User) Rule 2004 contains the regulations for driving a Forklift on a road. The Road Code is a plain english interpretation of the Land Transport (Road User) Rule 2004. The Land Transport (Driver Licensing) Rule 1999 contains the licence and endorsement requirements for a driver wanting to drive a Forklift on a road. The Land Transport (Driver Licensing) Amendment Rules contains updated information to the Land Transport (Driver Licensing) Rule 1999. The Truck Loading Code contains the requirements for safety of loads on vehicles.

5 The Safety Code for Forklift Truck Operators No 1, Front Loading Forklift Trucks contains the requirements for safe operation of forklifts. The Approved Code of Practice for Training Operators and Instructors of Powered Industrial Lift Trucks contains the requirements for Training operators of forklifts. NZ TRANSPORT AGENCY GENERAL If a Forklift is, at any time driven on a road, it has to be registered as a vehicle like other road vehicles and the driver/operator must satisfy two legal requirements: Be a licensed driver. Have an endorsement known as endorsement F on his/her drivers licence. (see driver licence requirements) To obtain an endorsement F, you are required to pass a prescribed course (by an approved course provider) comprising NZQA unit standard 18496 demonstrate knowledge and skills for driving a Forklift on a road for endorsement F (forklifts) . Candidates who show competency in this unit standard will receive a NZ Transport Agency certificate which is to be presented to a licence issuing agent (within 60 days of the date of issue) to have their current NZ drivers licence endorsed.

6 DRIVER LICENCE REQUIREMENTS DLAR 1 June 2006 If you want to drive a Forklift on a road and it has a gross laden weight (GLW) of no more than 18,000kg then you need to have a full NZ Class 1 Driver Licence and F Endorsement. If you want to drive a Forklift on a road and it has a gross laden weight (GLW) of more than 18,000kg then you need to have, at least, a full NZ Class 2 Driver Licence and F Endorsement. ROAD DEFINED The definition of a road includes: Streets, motor ways, beaches. Place s to which the public have access, whether as of right or not. All bridges, culverts, ferries and fords forming part of a road or street or motorway. All sites at which vehicles may be weighed for the purpose of the act. A road is essentially an area principally used for vehicles or pedestrian traffic, which the general public uses as thoroughfares to gain access to another place. In Practice this will generally be areas and thoroughfares that the general public use and expect to be able to use such as a road, street or supermarket car parks.

7 2016 FTC South NZ Ltd Forklift SAFETY Page 5 Access may be restricted by many devices including any or all of the following: Physical barriers. Security checks. Signs limiting that may enter or a condition under which access is permitted. LOADING VEHICLES General factors affecting the safe loading and unloading of vehicles on a road are: Other road users. Weather conditions. Light conditions. Road conditions. Forklift condition. (road safe) PARKING ON A ROAD When parking a Forklift on a road, the parking drill does not differ to that when parking in general; however the following considerations should be taken: Alternative fuel valves are closed. (if fitted) Battery master switch turned off. (if fitted) Key removed and Forklift secured. Do not park a Forklift on an incline, ramp, hill or slope.

8 Forklift DOCUMENTATION To legally drive on a Forklift on a road, the following documentation must be displayed: Registration plate. (rego) Licence label. Warrant of fitness. (WoF) DIMENSIONS AND WEIGHTS (forklifts with rigid suspension and single solid tyres on its axles) The maximum specifications allowed before a permitted is need are: Height or any lesser height. (to clear any construction or wire legally over the road) Width or from the longitudinal Centre line of the vehicle. Side overhang 200mm either side of the Forklift . Front overhang 3m from the front edge of the driver s seat to the end of the load. Front axle weight 6000kg single tyres. Front axle weight 8200kg twin tyres. REDUCE THE RISK To reduce the risk when loading and unloading vehicles consider the following: Ensure all vehicles are parked on flat ground. Place cones or temporary signs out if required. Ensure vehicle driver remains in a safe and visible position.

9 Have another person help with traffic control. Wear hi-viz clothing. Forklift STABILITY GENERAL An un-loaded (un-laded) Forklift is less stable laterally than a loaded (laden) Forklift and can be easily overturned when cornering. While the risk of overturning can be reduced the fact remains that there is always the potential for a Forklift to overturn. Consequently it is imperative that seat belts (operator restraints) are used to minimise the likelihood and severity of injuries should an overturn occur. To reduce the risk associated with over turning and tipping it is necessary to ensure Forklift load data information provides operators with comprehensive information on safe load capacities at all mast heights and tilt angles. Many rollovers involve un-loaded forklifts. 2016 FTC South NZ Ltd Forklift SAFETY Page 6 STABILITY ZONE Forklifts are designed on the principle of the see-saw and the stability of the Forklift is determined by the location of the Centre of gravity.

10 (or if the Forklift is loaded, the combined Centre of gravity) In order for the Forklift to be stable during operation, the Centre of gravity must stay within the area of the forklifts stability zone. This zone is an imaginary triangle drawn between the Centre of the two front wheels and the Centre of the rear axle. Centre OF GRAVITY The Forklift has moving parts and therefore also has a Centre of gravity that moves. This Centre of gravity moves forward and rearward as the mast is tilted forward and rearwards. The Centre of gravity also moves up or down as the forks move up or down. The stability of a Forklift can be affected by such factors as: Size, weight and position of load. The height the load is to be lifted to. Forward and rearward tilt. Inertia and centrifugal forces. Operating surfaces. Exceeding the rated capacity. If the Centre of gravity moves outside of the forklifts stability triangle this could cause the Forklift to tip/turn over.